Method for making shatter-resistant mirror

Abstract

A shatter-resistant mirror article and method for making same is disclosed wherein the back side of the mirror article is spray coated with two successive layers of a rubber adhesive composition with subsequent heat treatment steps wherein the mirror and layers are dried from the back side of the mirror outwardly to eliminate moisture and mirror defects and enhance adherence and shatter resistance.

What is claimed is: 
     
       1. A method of producing a shatter-resistant mirror article comprising: supporting said mirror with a back surface facing up;   preheating said back surface of said mirror by heat treatment at a pre-determined temperature which heats and evaporates any moisture on the back surface without blistering the mirror;   spraying a first layer of a rubber composition over said preheated back surface;   subjecting said first layer and back surface to heat treatment at a predetermined temperature which removes any moisture and preparatorily heats said first layer without scorching thereof;   spraying a second layer of said rubber composition over said heated first layer, and   said heat treatments and layer thicknesses being applied as to cause said layers to be dried outwardly away from said back surface;   whereby moisture is effectively removed from said back surface and composition layers to reduce mirror defects and enhance the adherence of said first and second layers and the shatter resistance thereof.   
     
     
       2. The method of claim 1 wherein said first and secnd layers are each approximately two mils thick. 
     
     
       3. The method of claim 1 wherein said first and second layers have a total thickness of approximately four mils. 
     
     
       4. The method of claim 1 wherein said rubber composition includes fifty percent solid content by volume. 
     
     
       5. The method of claim 1 wherein said predetermined temperature is approximately 225 degrees fahrenheit. 
     
     
       6. The method of claim 1 including providing an airless pump spray system by which said first and second layers are sprayed. 
     
     
       7. The method of claim 6 wherein said spray system is operated at a pressure of less than about 600 psi.